Prefeasibility Study on Balkh Carpet Value Chain, Jan 2008.doc text version ADB Rural Business Support Program (RBSP) Afghanistan Prefeasibility Study of Balkh Carpet Value Chain May 2008 Report Prefeasibility Study Program Project Funder Poverty Reduction Contract 30,2010 Program Asian Development Bank Program Officer Development Specialist Bank May 2008 funded by Japanese Fund for Ms. Donneth Walton Senior Rural Central and West Asia Department TA9100 AFG Contract Amount Implementation Budget Contract Period Republic of Afghanistan Implementing Consulting Asia Development November 10,2007 to November $5,644,000 Consulting Budget Executing Agency and Livestock Agency Rural Business Support $12,356,000 Ministry of Finance, Islamic Ministry of Agriculture, Irrigation Roots of Peace Organization Report Authors Kenneth Neils, PhD (Program Director), Roots of Peace, Vickie Sigman, Extension Specialist, Roots of Peace Roots of Peace Larry Hendricks, Credit Specialist, Alem Alemi, Deputy Team Leader, Roots of Peace Abstract This report is a prefeasibility study of the carpet value chain in Balkh Province of Afghanistan. The study focuses on the ability to positively impact the overall carpet value chain with specific interventions. This publication was produced for review by the Asia Development Bank. It was prepared by Roots of Peace. The author's views expressed in this publication do not necessarily reflect the views of ADB. This Prefeasibility Study was produced by Roots of Peace under the ADBfunded Rural Business Support Project (JFPR 9100AFG). It was written by Dr. Kenneth Neils, Acting Team with assistance Team Leader), Larry Kuhn Peace a from Dr. Hendricks of at Roots of RBSP Vickie (Credit the Staff, Sigman Rural including, (Extension Specialist). Peace. For Business Mr. Alemi Specialist), Study was Roots established organization in 1997, based focuses in on Project, Alem (Deputy and Mr. formatted info@rootsofpeace.org or +1 415 455 8008. notforprofit more The Support contact Peace, of of information, humanitarian, Roots Leader by Roots of Gary of Peace California, postconflict USA. is countries promote to eradicate economic remnants livelihoods of and war social and to reestablish and programs. Roots of Peace is funded by public and private sources. CURRENCY EQUIVALENTS (as of 30 January 2008) Currency Unit Afghani (Afs), Rupee (Rs) Afs1.00 = $.05 $1.00 = 50Afs $1.00 = 62Rs ABBREVIATIONS ADB AKDN AISA AREDP ARMP ASAP ASMED AWBF DAIL HLP MAIL MFI MISFA M&E MRRD NGO PFI PHDP RBSP ROP SSPSRL TOT USAID Asian Development Bank Aga Khan Development Network Afghanistan Investment Support Agency Afghanistan Rural Enterprise Development Program Afghanistan Rural Microcredit Program Accelerating Sustainable Agriculture Program Afghanistan Small and Medium Enterprise Development Afghan Women's Business Association Department of Agriculutre, Irrigation, and Livestock Horticulture and Livestock Program Ministry of Agriculture, Irrigation, and Livestock Microfinance Institution Microfinance Investment Support Facility for Afghanistan Monitoring and Evaluation Ministry for Rural Rehabilitation and Development Non-Government Organization Participating Financial Institutions Perennial Horticulture Development Project Rural Business Support Project Roots of Peace Support to Strategic Planning for Sustainable Rural Livelihoods Training of Trainers United States Agency for International Development WEIGHTS AND MEASURES kg ser Kilogram or kilograms 7 kilograms NOTE (i) In this report, "$" refers to US dollars, "Afs" refers to Afghanis, the currency of Afghanistan and "Rs" refers to Rupees, the currency of Pakistan. Balkh Carpet Value Chain Prefeasibility Study 3 CONTENTS 1. EXECUTIVE SUMMARY ............................................................................. .................... 5 2. INTRODUCTION ............................................................................. ................................ 6 3. VALUE CHAIN DESCRIPTION ............................................................................. .......... 7 4. MARKET ASSESSMENT ............................................................................. ................... 9 4.1. Demand and Supply ............................................................................. .................... 9 4.2. Production Costs ............................................................................. ....................... 11 4.3. Processing Costs ............................................................................. ....................... 12 4.4. Marketing Costs ............................................................................. ......................... 12 4.5. Price Trends ............................................................................. .............................. 12 4.6. Prices and Value Added Along the Value Chain .................................................... 12 4.7. Estimated Increase in Revenue ............................................................................. . 14 5. KEY CONSTRAINTS/GAPS ............................................................................. ............. 16 5.1. Raw Wool ............................................................................. .................................. 16 5.2. Wool Scouring ............................................................................. ........................... 16 5.3. Spinning ............................................................................. ..................................... 16 5.4. Dying ............................................................................. ......................................... 16 5.5. Design ............................................................................. ....................................... 16 5.6. Weaving ............................................................................. ..................................... 17 5.7. Finishing: Cut and Wash ............................................................................. ........... 17 5.8. Marketing ............................................................................. ................................... 17 5.9. Organization ............................................................................. .............................. 17 5.10. Credit ............................................................................. ..................................... 18 5.11. Subsidies ............................................................................. ............................... 18 6. OPPORTUNITIES ............................................................................. ............................ 19 7. OTHER DONOR PROJECTS ............................................................................. ........... 21 7.1. Carpet Sector Development: National Level .......................................................... 21 7.2. Training/Capacity Development ............................................................................. 22 7.3. Existing Institutional Capacity ............................................................................. .... 23 7.4. Existing Groups/Associations ............................................................................. .... 23 8. CREDIT MAP: BALKH CARPET ............................................................................. ...... 24 9. PROPOSED INTERVENTIONS ............................................................................. ....... 27 9.1. Description ............................................................................. ................................. 27 9.2. Strategic links to existing programs ........................................................................ 28 9.3. Stakeholders Interest in Value Chain Improvement ............................................... 28 10. INDICATIVE NUMBER OF POTENTIAL BENEFICIARIES ....................................... 29 11. RECOMMENDATIONS ............................................................................. ................. 30 11.1. Feasibility ............................................................................. ............................... 30 11.2. Cost Effectiveness ............................................................................. ................. 30 11.3. Risk Manageability ............................................................................. ................. 30 11.4. Financial Viability ............................................................................. ................... 31 11.5. Environmental Issues ............................................................................. ............. 31 ANNEX 1: VALUE CHAIN FOR BALKH CARPET ................................................................ 32 ANNEX 2: CREDIT MAP: BALKH CARPET ......................................................................... 33 Balkh Carpet Value Chain Prefeasibility Study 4 1. EXECUTIVE SUMMARY One of the principal provinces in Afghanistan where carpets are made is Balkh province. Balkh Approximately There are has a long onefourth over 1.7 of and all million rich history villages square in meters of carpet Balkh of weave carpets weaving. carpets.1 produced in Balkh and the northwest provinces. There are over 100,000 families in this region involved in producing carpets. Although the Afghan handmade are the prize export of Afghanistan, much of the value added is lost to Pakistan. Pakistan carpets, including receives a similar an estimated 80% to 95% of Afghan percentage from Balkh. Carpets are then finished and reexported as Pakistani carpets. Pakistan brands Afghan carpets and exports onwards, primarily to Europe and the USA. The great majority of Afghan handmade carpets go through Pakistan due: (i) to the lack sufficient cut and wash longterm relationships partners and limited partners, to carpets with trading (iv) facilities Pakistanis their Afghanistan, have established international relationships to in relatively trading between low Afghans cost of (ii) with partners, and shipping of to the their Afghan (iii) to international from Afghanistan Pakistan versus high cost of shipping from Afghanistan to international markets, and (v) Pakistan's advantage in that the Pakistan Government subsidizes has an Pakistan's opportunity, carpet if it industry. gets The better Afghan carpet organized, to industry capture more of the value of its prized carpets by adding value to the wool that is used for its carpets and by establishing its own proper cut and wash facilities and direct marketing when they capability. are buying wool Afghan in traders are and bang for weavers the all high-quality buck”. have a opportunistic Pakistan or in Iran. The wool traders are not necessarily looking for the same wool that “best quite Afghan stake in wool the would give cleaners, carpet the spinners, industry. weaver the dyers, They require inputs. Overall, the wool and carpet value chain in Afghanistan requires the quality and the demand driven incentives to be captured by the Afghan producers. The feasibility of cut and wash facilities has been investigated and the results indicate a very high return. marketing of carpets branded by Afghan exporters The also potential as long as the shipping costs can be managed. the weavers of Balkh need a chance to access direct has In their tremendous addition, own inputs independently, own their own looms, learn about the designs in most demand, establish Afghan cut and exporters wash with facilities, direct and linkages send to their carpets lucrative markets. through These value-added activities are feasible and if implemented could lead to very significant increases in income to stakeholders working within the value chain in Balkh. 1 Ministry of Rural Rehabilitation and Development (MRRD). 2007. Feasibility Study for Carpet Subsector Plan: Operationalizing Cut and Wash Facilities. Kabul: MRRD. Balkh Carpet Value Chain Prefeasibility Study 5 2. INTRODUCTION Afghanistan countries, has had producing a long hand woven tradition carpets in, made and from is one wool, of few cotton, and/or silk. Prior to the 1990's, Afghanistan was a very important player in the global carpet market. Over the period 1990 war and civil nor internationally Pakistan. strife, The Afghanistan and revival lost of was its the not share able of 2002, to the export market, regionally largely involved cut wash operations, and design development1. While figures vary supporting activities such as wool production, the Ministry of Commerce, International Trade Department, based on CSO data indicate Afghanistan annually through average $176 formal to additional millions widely, information from the estimates there are over one million Afghans working in the production of carpets with and to carpet industry in Afghanistan began in 2002. The Afghanistan Carpet Exporters Guild in due market channels, an of exported, million worth of carpets over the period 20032006. Of this, annual exports estimated at $164 million went to Pakistan through formal market channels. This official estimate underestimates the actual carpet exports. If the informal trade of carpets is included, it has been estimated that Afghanistan produces annually about 6.6 million square meters which are exported.2 The value of of 6.6 handmade million carpets is at least twice the official data. Afghanistan are viable visible focus and for globally both acknowledged products and one become major most development producing areas of carpets is Balkh. Balkh has a long and rich history of carpet weaving. villages in Afghanistan's a of meters of carpets of most Afghanistan's government and private sector support organizations.3 One of the major all square The as have carpets, in Balkh weave carpets.4 Approximately There are over onefourth 1.7 of million square meters of carpets produced in Balkh and the northwest provinces. There are over carpets. 100,000 The families average carpet weaver meters of homes. Because so impact of income the strongly felt. in per year. many this in involved Afghanistan in produces producing about 18 square The weaving is done mostly by women in women these region are women involved bring to in weaving, their the their economic households is This document presents information collected from field trips in Balkh province, from donor project documents, and from discussions with various Kabul based stakeholders. 1 the provides a development summary of of this the study. The findings At the schematic of top the of presented field the work in ANNEX leading schematic is to a brief outline of the value chain. The horizontal sections below the outlined value chain set out improvement and the constraints/gaps, suggested opportunities for value chain strategic interventions for the RBSP program. The remainder of this study provides the information and prefeasibility analysis of interventions in the carpet value chain. 2 Landell Mills, Ltd. 2007. Preparing the Commercial Agricultural Development Project, Main Report, Phase 2. Asian Development Bank Project. 3 McCord, M. May 2007. An Analysis of Business Opportunities within Afghanistan's Carpet Sector. Kabul. 4 Ministry of Rural Rehabilitation and Development (MRRD). 2007. Feasibility Study for Carpet Subsector Plan: Operationalizing Cut and Wash Facilities. Kabul: MRRD. Balkh Carpet Value Chain Prefeasibility Study 6 3. VALUE CHAIN DESCRIPTION There are many steps in the carpet value chain. The initial steps involve obtaining the the wool of sheep. purchasing the quality and source of raw wool needs to be considered and is contingent Some proper quality and volume of wool, including: on the The fibers, the breed best wool of wool is for sheep and carpets highlyprized availability, comes for its from respectively. Afghanistan's Ghazni texture, long length and for its high proportion of white wool. Other wool of of various quality types originates from the Middle East and is imported from Pakistan or Iran. washing the wool scouring. Wool scouring nonwool contaminants. wool) by spinning brushing the wool or by machine. on handspinning Raw wool requires proper washing, that is, uses hot water with detergent to remove the oil and carding/combing the wool into Even yarn though wheels, has desired for highquality carpets. fibers by with hand, handspun an (following the drying, of the wire teeth to align the fibers. by use yarn, of which spinning includes wheels, yarn spun uneven structure, this look is frequently dying the wool, an intricate process requiring and extensive pH) of used. dyes Most from carpet knowledge and and colors. carpet Both weavers traders and, experience chemical obtain their as well as temperature and dyes natural wool and other are inputs therefore, are not involved in the above steps. The traders also provide carpet designs designs, (controlling the to contemporary the weavers. designs, The reflect traditional buyer preference, and are graphed, showing both color and pattern. Graphing is done by hand in is famous Northern madeup more Pakistan for "Chob typically carpets patterns are based on floral Carpet receive their on master graphers. design, woven Traditional dark red carpets are in or pastel mainly Turkmen in design burgundy woven Afghanistan base. with is The natural colors. Afghan Kazak traditional Caucasian designs and woven with good weavers loom a designs quality wool yarns, much of which dyes. Balkh. Rang" having by Turkmen including geometric recent Afghanistan traditional Afghanistan, of dyes, its and may from has been dyed using natural vegetable have the their own loom or they may carpet trader. Depending on the size of the loom, up to five people can work together on a single carpet. Wooden or steel, horizontal or vertical, looms ranging in size from 2 to 25 meters square. An expert weaver can produce around two square meters of carpet per month, in the although design and this varies 40 the density of knots required with the experience of the weaver. There are three major standard densities, measured are: 35 x 35, with as number of knots per 10 cm squared. x 40, and 50 x 50. The These higher the density, the higher the quality and price of the carpet. The cut and wash process following weaving cleans the carpet, restores the original shine of the wool, and brings out the carpet's sheen and luster. There are three types of washing that produce carpets of different degrees and luster. These are: Antique wash gives an old look to the carpet Balkh Carpet Value Chain Prefeasibility Study 7 Tea wash gives a shiny look After the carpet shaved) to traders who carpets, in a dried uniform have the carpet's level. to weavers Pakistan. Traders surface Marketing contracted primarily Afghanistan. loom, is Simple wash gives an original color look to is contract and weaving weavers, cut (clipped or largely by accomplished weave Contract is who is then very providing sell widespread them with the yarn, and design, and pay them a per meter wage ranging from $31 depending on carpets, typically linked have to $50 intricacy of design, knot density, quality, and size of carpet. Some weavers are paid up to density the this contracts end independently but buyers sell $79 in their per is meter very with for unusually infrequent. Pakistan buyers, international high Merchants who markets. are Some knot themselves directly weavers carpets in local markets. Balkh Carpet Value Chain Prefeasibility Study 8 4. MARKET ASSESSMENT 4.1. Demand and Supply 4.1.1. Demand By Product Type This report focuses on handmade knotted carpets. Demand for the carpets is dictated by make (wool, cotton, and/or silk), design, wash type, quality in terms of number of knots European market prefers carpets Wash technique, whereas the been Tea Washed. study referenced that American are location Simple that have The OTF carpet trading, Local and Provincial networks, and Mazar services with indicating 90% of carpets produced in Balkh transfer through Mazar to Pakistan. National domestic Afghanistan. demand Reports are purchased in Afghanistan5. direct carpets The in this study has a detailed description of the demand for for limited etc. the The Antique wash has a niche in both markets. is estimates inch, using market prefers By Geographical Location key square finished handmade carpets. a per demand, Pakistan Relative for to carpets that around domestic at 8% the of demand, nationallevel Afghan an estimated 80% is in carpets Regional and International receives there are Although to 95% of not a Afghan carpets. Carpets are then finished and reexported as Pakistani carpets. Pakistan brands Afghan carpets and exports onwards, primarily to Europe and the USA. This is due: (i) to the facilities in (ii) Pakistanis have their Afghanistan, established international relationships relatively low with trading between cost to of longterm their and shipping sufficient the partners, Afghans of lack Afghan (iii) and to wash relationships partners and limited international from cut trading partners, Afghanistan to with (iv) to Pakistan versus high cost of shipping from Afghanistan to international markets, and (v) Pakistan's advantage Pakistan's carpet in that industry. the Pakistan Government subsidizes Reports state there are over $1.4 billion in carpet sales on the world market each year.6 Around 70% of global demand for carpets is from five countries: United Arab Emirates, Italy, Germany, USA, and UK7. The USA and Germany purchased $531 million and $300 of the carpet in 2004. The US demand grows slightly million annually, German demand has fallen rapidly over the period 1998 worth while 2004. 5 6 7 OTF Group. 2006. Afghanistan Competitiveness Project Key Documents Library: Volume 2. Kabul. McCord, M. May 2007. An Analysis of Business Opportunities within Afghanistan's Carpet Sector. Kabul. OTF Group. 2006. Afghanistan Competitiveness Project Key Documents Library: Volume 2. Kabul Balkh Carpet Value Chain Prefeasibility Study 9 For Close Substitutes -are The increasingly method of Machinemade becoming production more is carpets--from attractive reportedly way the product is styled and colored. 4.1.2. Supply now to Iran, China, international less and India- buyers. important than the By Product Type This study focuses on handmade knotted carpets. The supply of carpets is limited by the handmaking the carpets if weavers would carpets. they had time Some that if they could are produced (namads/lamsai) represent a and in flat learn small carpets widespread has in increasing. more weaving of floor carpets However, these used in the homes of the weavers who By Geographical Location Local Discussion with officials in Balkh and in several districts in Balkh confirms that Dawlat and good types wool to potential about (kilims). produce them. Rarely are they exported. weaving weave New other devote percentage, about five percent, of all floor coverings produced in Afghanistan8. Most are and Provincial more Two to would looms. Afghanistan--felted woven have weavers better techniques and could afford the loom. coverings weavers experienced differentsized weave, the the highest Dehdadi The Abad and Ministry is number Nahri of the Rural district most wellknown of weavers. Weaving is Shahi, although its importance Rehabilitation and Development for less is (MRRD) National AreaBased Development Program has been instrumental in assisting districts develop their district development plan. District Development Plans for Dawlat mention the positive Abad, impact of Dehdadi, carpet and Nahri weaving Shahi each activities in their district on the economy of the district. Most carpets produced in Balkh shipped of to carpet Pakistan via Mazar. While unavailable. information on amount districtlevel information is currently It is widelyheld that Balkh is one of Afghanistan's most important provinces for carpet production. square meters of carpet were exported through formal market channels.9 of is shipped to Pakistan from Mazar, this information is not disaggregated by district. Thus, Agency there are Afghanistan from Estimates are that 1,700,000 Mazar to Pakistan in 2005 National suggests annual The production Export to be Promotion in the area of two million carpets with an average size of 3.2 meters square. This results in an carpet. 8 9 annual Adjusting estimate this figure of around 6.4 million square meters of OTF Group. 2006. Afghanistan Competitiveness Project Key Documents Library: Volume 2. Kabul. Landell Mills, Ltd. 2006. Preparing the Commercial Agriculture Development Project: Phase 1 Report. Kabul. Balkh Carpet Value Chain Prefeasibility Study 10 based on more recent data from Mazar, Herat, Kabul, and Andkhoy, results in an annual the estimate of 6.6 million square meters.10 largest Afghanistan. While supplier of Table shows Afghanistan 1 appears carpets, top followed suppliers third, while being based Pakistan on Iran is and value of exports. Afghanistan supplies significantly more carpet than the table suggests because much of underreported by Regional exported to its Pakistan production where it is is re exported as Pakistani. Table 1. International Carpet Market: Top Suppliers Carpet Exports Country (Millions $) Iran 391 Pakistan 246 Afghanistan 149 India 148 China 121 Nepal 100 Source: OTF Group. 2006. Afghanistan Competitiveness Project (Key Documents Library: Volume 2. Kabul) Of Close Substitutes Afghan handmade carpets China, and from Iran, carpets is less important with machine-made India. The supply of machine-made carpets continues to grow and as mentioned above, production compete than how reports the indicate carpet is the method of styled and colored. 4.2. Production Costs The margins represented in the value chain for carpets exported from Balkh to Pakistan and then on to the European market are given in the following table: Table 2. Carpet Value Chain Activity Raw wool Dying Weaving Transport to W/S market Wholesale price Transport to Peshawar Cut and wash repairs Wholesale Peshawar Transport to Europe Wholesale Europe Retail EUROPE Margin (Rs) 999 245 2759 150 2495 92 300 104 1033 61 1778 1839 Margin ($) 16.30 4.00 45.01 2.45 40.70 1.50 4.89 1.70 16.85 1.00 29.00 30.00 Source: Landell Mills, Ltd. 2006. Preparing the Commercial Agriculture Development Project (Phase 1 Report. Kabul) 10 Landell Mills, Ltd. 2006. Preparing the Commercial Agriculture Development Project: Phase 1 Report. Kabul. Balkh Carpet Value Chain Prefeasibility Study 11 The graph of the margins within the value chain for carpets is given in Figure 1 below. 4.3. Processing Costs Cut and meter wash in processing Pakistan. costs are the silo high quality at $8.00 per square There are cut and wash facilities in Kabul, Mazar, and Herat. The quality of these varies, near estimated in Mazar, services, run but by although is the at generally Naim higher low. Company, prices One service reportedly than its offers local competitors.11 There are indications that cut and wash in Afghanistan ranges from $4 $7 USD per square meter. 4.4. Marketing Costs Transport from destinations is Kabul to Pakistan lower, onwards to international one marketing cost. Costs from Kabul to Pakistan are between $6.50 and $7.00. Costs of much and estimated at transport around $3.00. from This Pakistan is to UK are largely because the former is by truck/road and the latter by container/sea. Afghanistan exporters would have an advantage shipping to the US in that carpets may be shipped to the USA duty free. Considerable investment is required to develop and expand markets marketing costs and are advertise covered products largely internationally. Currently, by the Pakistani traders, but there are reports that the Pakistan Government subsidizes the container shipments of its carpets. 4.5. Price Trends International inflation prices rates of for carpets the generally follow and Germany grew by respectively. In general, international prices market and prices have followed about 3% and 7%, for carpets steadily grew with the low inflation rates in these countries. in growth major international economies. Over the period 20022004, the carpet market in the US trends the the More specifically, quality, styles, the and colors demanded by the international market. The best growth in carpets accompanied by higher prices has been in the soft contemporary designs. The market for high quality, traditional carpets is not growing, but slowly losing out to the contemporary style. The has become less popular, with a market sales for decline Chob of Rang 25% carpets having taken place in recent years.12 4.6. Prices and Value Added Along the Value Chain The price of wool varies the market Carpets for the local market at the bottom end of use Iranian wool costing about US$1.00 per kilo. The finished carpet sells for about $25/ m². On the high end, `Belgique' wool, imported machine spun wool, retails for US$6.00 carpet sells for $about as much to US$7.00 per as $150/ m². Part of kilo. The finished the difference in the costs is from the price of the wool and the other is from the knot density, finer and which the is knot higher with the imported wool, as the wool is density is 55 x 60 per 10 cm. 11 MRRD. 2007. Feasibility Study for Carpet Subsector Plan: Operationalizing Cut and Wash Facilities. Kabul: MRRD. 12 OTF Group. 2006. Afghanistan Competitiveness Project Key Documents Library: Volume 2. Kabul Balkh Carpet Value Chain Prefeasibility Study 12 Besides the dictated wool. The prices by the price of the number paid of to inputs, knots the the per weaver, prices 10 cm minus of and input carpets by the are type of costs is given in Table 3. Table 3. Cost Structure and Percentage of Carpets Woven Item 30-35 double knots 35-50 double knots per 10 cm per 10 cm (Iranian wool) (Iranian wool) US$ US$ Cost per m² 25-30 40-50 Percent of total 25 percent 40 percent carpets woven Note: Carpet prices are also lower by 10% or more for carpets that have flaws. 50-60 dbl knots per 10 cm (Belgium wool) US$ 100-120 35 percent Most woven carpets and are before exported from Afghanistan after they have been they are cut and washed. Most Afghan carpets are cut and washed in Pakistan and then marketed to international markets. The prices for the different quality of carpets in the US are given in Table 4. Table 4. Price Structure for Different Grades of Carpets in US$13 Knot Density Best Good 35x40 90 85 40x40 107 98 50x50 131 115 Bad 74 79 82 Note: Where Best represents the top style, excellent quality, and preferred color; Good represents less popular style, good quality, and average color; Bad represents relatively unpopular, fair quality, and poor mix of colors. Landell Mills, Ltd. 2007. Preparing the Commercial Agricultural Development Project, Main Report, Phase 2. Asian Development Bank Project. 13 Balkh Carpet Value Chain Prefeasibility Study 13 The graph of the margins within the carpet value chain is given in Figure 1. Figure 1: Carpet & Wool Value Chain Margin in US$ Figure 1: Carpet & Wool Value Chain Margin in US$ 250.00 200.00 Retail Europe Wholesale Europe 150.00 Transport to Europe Wholesale Peshawar Margin in US$ repairs Cut and wash Transport to Peshawar Wholesale price Transport to W/S m arket 50.00 Weaving Dying Raw wool 0.00 1 Activities 100.00 4.7. Estimated Increase in Revenue The project will provide technical assistance and training (in accessing quality inputs, in flaws in year weaving) period. their about trained because preferred, three to The carpets more developing weavers and per demanddriven designs, 600 households weaving weavers the the will carpets inputs receive do are not of correcting over $5/sq.m. have higher in flaws, the two more for the quality. all design is Assuming household with an average production of 18 square meters per weaver, the estimated increase in revenue is $162,000. Many weavers do not own their own looms; instead they pay the traders who rent them looms for $4/sq.m. of carpet. Through the support of the Project, two hundred weavers will purchase steel looms on credit. The average weaver household produces 54 sq. m. of carpet per year. The estimated increase in revenue for the 200 weavers is $43,200. many weavers in the Balkh Many people districts who are hand spin wool including spinning 0.2 kg of wool per day and receiving $0.63 kg/day. The Project will assist 200 spinners who using are spinning interested in wheels in purchasing and wheels to increase their spinning to 1.2 kg/day. The increase in rate of spinning is 0.9 wheels spinning for 300 kg/day. days/year, the If the 200 estimated spinners use the spinning increase in their revenue is $43,020. The Project will assist two investors in establishing two cut and wash facilities in Balkh washing at province each with a capacity for cutting and least 90,000 sq.m. of carpets Balkh Carpet Value Chain Prefeasibility Study 14 per annum. cut and will Instead wash, be cut of it and is the estimated washed per $5.50/sq.m. is $990,000. Project sq.m. will of assist carpets Balkh that annum. Once the carpets the being approximately to Pakistan 180,000 sq for meters The estimated increase in revenue at carpets carpet exporters to international directly sent are in cut and exporting markets washed, the the 180,000 bypassing Pakistan. By eliminating Pakistan from the value chain, the Pakistan exporters will save increase in at revenue 2,880,000. least from $16 of marketing gross the revenue. The estimated 180,000 sq.m. is about The total estimated revenue from the Project interventions is $4,046,130. Balkh Carpet Value Chain Prefeasibility Study 15 5. KEY CONSTRAINTS/GAPS While Pakistan Afghanistan's represents a prime constraint to the improvement of position in the global value chain, Pakistan also provides inputs and services currently in short supply in Afghanistan. This is the foremost challenge facing the Afghan carpet industry. Other specific constraints and gaps in the value chain are discussed below. 5.1. Raw Wool Local Ghazni wool, considered of very high quality, accounts for about 15% of wool used in Afghanistan.14 Because demand is greater than supply, Afghanistan imports raw wool, primarily from Pakistan. 5.2. Wool Scouring A growing concern for the environment has led to increased demands on the scouring process. environmental Afghanistan Improved concerns wool is technologies related scoured to are wool using available scouring. traditional to address However, in processes. There are currently no improved facilities for wool scouring in Afghanistan. Few merchants have adequate space for drying and storing wool. 5.3. Spinning Wool is traditionally handspun in Afghanistan. There are few small wooden spinning wheels in Afghanistan and most weavers have reportedly never used spinningwheels. Much of the yarn used in Afghanistan is imported, already spun, from either Pakistan or Iran although Mazar has one private yarn producing company. The company has been in years and imports wool from Iran, operation Uzbekistan, for and the past three Pakistan. 5.4. Dying There yarn are is Dying a number dyed is of using becoming smallscale natural a lost facilities dyes. art However, and in Afghanistan there are few Pakistan where Balkh. medium or largescale factories in Afghanistan dying wool using natural dyes. There are in in materials required for natural dyes are becoming more difficult to source. There are no factories where chemical dyes are used to largescale produce large quantities of dyed yarn. Afghanistan imports much of its dyed yarn from Pakistan and Iran. 5.5. Design Reports are constraint Afghan that in weavers the the via time carpet required weaving Pakistan, to hand process. again tying As copy well, designs designs within making changes difficult for Afghanistan to international market preference and demand. a come to Afghan traders and weavers to Pakistani merchants. There is a lack of design expertise it is respond to Afghanistan in 14 MRRD. 2007. Feasibility Study for Carpet Subsector Plan: Operationalizing Cut and Wash Facilities. Kabul: MRRD Balkh Carpet Value Chain Prefeasibility Study 16 5.6. Weaving Contract weavers dictated by incentive that those than weavers often have with whom required who have no to alternative they contract produce their own to accepting and may high quality looms are have carpet. paid conditions less Reports around are $4.00 more per square meter for their work than weavers who are provided looms by their contractor. As well, there are indications weavers who purchase their own inputs can make more money, but this assumes they can sell their carpet at good price and few weavers are directly linked to good markets. Quality is an important issue for weavers and traders alike. Weavers who produce poor quality carpets receive less money (2000 produce high negotiating quality capacity carpets and (3500 Afs/sq Afs/sq organization to meter) meter). than those Weavers advocate for who lack better wages, working conditions, and/or initiate direct marketing. Although Balkh has a tradition of producing high quality carpet, the handmade carpet industry is very competitive, with market shares contingent on production of high quality products. 5.7. Finishing: Cut and Wash Reports suggest Afghanistan 10% with finishing.15 There to the are 20% large a of Afghan majority few cut carpets are finished in to Pakistan for transported and wash facilities in Mazar, Herat, and in Kabul. In Mazar, there are a total of ten facilities. These provide finishing these services for Afghan customers and the quality of operations, is with considered services, a to few be although exceptions, competitive, at a higher is low16. providing cost Out high than the of the quality other ten, one finishing operations. Pakistan's weather is a comparative advantage in cut and wash compared to most carpet carpets parts making in of cold locations weather, Afghanistan a in Afghanistan. condition which exists in It the is difficult central and northern expertise required to add value via cut and wash processes. Chemicals required for cut imported increasing There is from the Pakistan cost little of work and cut have and being done dry anywhere from four to six months of the year. Few Afghans have the technical skills and are to a wash on short shelflife, operations in and wash thus Afghanistan. identifying better sources of chemical or better chemicals for the cut and wash process. 5.8. Marketing As earlier mentioned, the handmade carpet industry is highly competitive. Cuttingedge marketing skills, linkages, and technologies are needed to enable Afghan merchants to successfully compete. Few Afghan traders are linked to international markets. Few are able to direct market over the internet. Most are tied to buyers in Pakistan. There is an almost complete lack of branding of Afghan carpets as most are exported as a Pakistani product. 5.9. Organization There are two large trader organizations operating in Balkh. While they represent large below, and their they lack numbers of professional the traders and weavers, organizational expertise required and as business further skills detailed are weak to 15 MRRD. 2007. Feasibility Study for Carpet Subsector Plan: Operationalizing Cut and Wash Facilities. Kabul: MRRD. And McCord, M. May 2007. An Analysis of Business Opportunities within Afghanistan's Carpet Sector. Kabul. 16 Ministry of Rural Rehabilitation and Development (MRRD). 2007. Feasibility Study for Carpet Subsector Plan: Operationalizing Cut and Wash Facilities. Kabul: MRRD. Balkh Carpet Value Chain Prefeasibility Study 17 trade effectively in there are groups weaver weaverrelated issues. the international in Balkh, However, most market. concerned are There are primarily indications with reportedly small and few are wellorganized. 5.10. Credit Traders report constraints in their cash flow weavers working. Weavers may need credit other inputs. All advise they lack access to credit. This is not only a to to keep contract purchase new looms function of credit availability, but of their ability to obtain credit and their concerns over what they or credit consider high and/or worthiness interest rates as well as their concerns about loan repayment. 5.11. Subsidies The Pakistani the Union government subsidies its carpet industry. For example, President maintains the Pakistani Government provides a bonus to its traders of $5,000. for every 40 foot container of carpets shipped out of Pakistan. Afghan merchants believe these types of subsidies put them at a distinct disadvantage and they frequently request assistance. Balkh Carpet Value Chain Prefeasibility Study 18 6. OPPORTUNITIES some type of government The Afghan Investment Support Agency (AISA) is a onestop shop supporting investors. They have studied investment opportunities in the carpet industry advising: "Wide opportunity exists for investors to add value to their products by controlling the highly profitable activities closest to the end customer. It is estimated that the value of Afghanistan's entire carpet industry would increase between two and five times if companies finished goods in country and sold directly to overseas markets, rather than exporting through intermediaries. Handling all aspects of production within Afghanistan would allow for enhanced quality and a revitalized, "Made in Afghanistan" brand of carpets marketed for export worldwide. Along the supply chain, investment opportunities include: wool production, dye manufacture, carpet finishing, international marketing services, and transport and logistics."17 The Afghanistan project Small and Medium Enterprise Development (ASMED) conducted a review of the carpet sector and identified investment opportunities in the sector.18 The table below draws on ASMED data, already referenced, and field sources work conducted for this study. Table 5. Constraints/Gaps and Opportunities in the Carpet Value Chain Constraint/Gap Opportunity Limited supply of high-quality Afghan raw wool Lack of improved scouring facilities Spun yarn imported from Pakistan Expertise to use and to source natural dyes is limited from Pakistan inefficient Dyed yarn imported Traditional techniques for design development and copy are Lack of Afghan design capacity decreases opportunity to respond to changing international design preferences 17 18 Increase flock size Grade and brand Afghan wool Facilitate establishment of facilities utilizing improved technologies for washing/drying/storing wool Increase quantity of hand-spun wool in Afghanistan by introducing and testing spinning wheels19 Institute an apprenticeship program to expand the number of people with expertise in using, sourcing, and marketing natural dyes Facilitate establishment of a medium-size facility to produce naturally-dyed hand-spun yarn Explore feasibility of Computer Assisted Design technologies to speed-up design drawing and copying process Provide opportunities for several artisans to further develop their design expertise through regionally-based training Develop Afghanistan-based design services to collect market information about designs and colors for Afghan Available: http://www.trade.gov/static/afghanistan_carpetstextiles.pdf ASMED. September 2007. Presentation: Investment Opportunities in Afghan Carpet Sector. Kabul. 19 The Indigo Carpet Association, based in Kabul, produces and promotes hand woven carpets using hand-spun wool and natural dyes. The Association has experience with spinning wheels, having provided spinning wheels to women with whom they work in Herat. These women were able to increase their production of spun wool by 400%, thereby significantly increasing their incomes. USAID. January 2008. Accelerating Sustainable Agriculture Program: Annual Report 1, November 22, 2006 December 31, 2007. Kabul Balkh Carpet Value Chain Prefeasibility Study 19 Constraint/Gap Limited attention to weaverrelated issues Opportunity merchants/weavers Boost motivation for weavers to produce high- quality carpet by facilitating loom ownership, providing targeted training to improve weaving skills, facilitating weaver access to higher-quality inputs, and initiating an association-based quality improvement and control program Facilitate establishment of medium to large-scale facility providing feebased quality finishing including labeling services to production units, traders, and associations The potential demand for cut and wash facilities in Balkh beyond the 5000 sq.m. capacity that exists is estimated at 55,000 sq m per month20. Assist merchants to initiate/improve direct marketing activities including website development, linkages to international web-based marketing, inventory management, branding, sea and air shipping, and customs clearance procedures Strengthen merchant capacity to articulate market issues and concerns to related national agencies and government Afghan participation in international trade shows Facilitate Assist existing, organize new associations to strengthen trader/weaver capacity to produce, negotiate, and market Develop groups/associations to empower weavers to advocate for better wages, working conditions, and/or to initiate direct marketing Broker linkages among weavers/merchants and credit suppliers Limited number of highquality cut and wash facilities in Afghanistan; in Balkh the capacity of the existing cut and wash facilities is about 5000 sq.m. per month; Most carpets sent to Pakistan for finishing Afghan merchants linked primarily to Pakistan, not directly to international markets Afghan merchants unable to effectively advocate with Government Limited capacity of existing trader unions/associations groups/ associations Few or weak weaver Lack of capital 20 MRRD. 2007. Feasibility Study for Carpet Subsector Plan: Operationalizing Cut and Wash Facilities. Subsector Analysis and Business Plan Development/ North and Northeast/Economic Viability and Technical Feasibility. Balkh Carpet Value Chain Prefeasibility Study 20 7. OTHER DONOR PROJECTS 7.1. Carpet Sector Development: National Level There are sector at three the Competitiveness Enterprise in 2008; major nationallevel. Project, Development and projects the addressing These completed Program Afghanistan are in the 2006; (AREDP) Small development (ASMED) project currently in operation. the Medium was completed in 2006. The carpet Afghanistan to begin Rural implementation Enterprise Development The Afghanistan Competitiveness Project, funded by USAID and carriedout by the OTF and the Afghanistan planned and of project helped Group, began develop in 2004 a nationallevel strategy for growth of the carpet sector, provided institutional support to the development of the Afghanistan Carpet Committee in the Ministry of Commerce, and supported an outreach effort to address general instrumental competitiveness in establishing issues.21 the The national project framework Afghanistan's carpet industry is currently operating. Rural Rehabilitation and Development (MRRD) is was very within The in which Ministry of process of the developing the AREDP which is to be funded by a group of donors. This is a largescale national program, designed for a 10year period with a funding base of $568 million, to facilitate enterprise development in rural communities, to support policybased lending enterprises, and enterprises.22 operate at to provide This the a national range and efforts, some activities that test quarter. close of in AREDP its the will As begin AREDP Enterprise be currently have in between the Development two be RBSP intends must Details of in a the ensure USAID AREDP Plans are fourth there Afghanistan (ASMED), to pilotproject likely projects. project AREDP determined. 2008, implementation, and on products in operation. to to communities through in and services carpets. yet implementation begins reach methodology carpetsector collaboration Medium are business will will project which communities AREDP will focus strategic subsectors, among these develop of program communitylevel. to is Small and funded project, is an important actor in the carpet value chain, as well as in other value chains in Afghanistan. development activities development, alliance ASMED the in in Kabul and nationallevel ever The business five sector to workforce associations in service capacity trade International assists economic publicprivate international Afghanistan project main business development, delegations first 2007. private on marketing, association sponsored sponsored focuses including: business creation, has ASMED the provider sector development. fairs Carpet and Fair development held of such as the Afghan Carpet Exporters Guild, the Kabul Carpet Association, and the Export Promotion Agency of Afghanistan. ASMED is interested in a strategic alliance with RBSP in to support related to the the development small and medium enterprises carpet sector there. The concept is one of a joint venture whereby the two projects pool enterprises 21 22 of Mazar which resources will support to the facilitate carpet the development of Available: http://www.trade.gov/static/afghanistan_carpetsummary.pdf MRRD. No Date. Draft Program Document. Afghanistan Rural Enterprise Development Program. Kabul. Balkh Carpet Value Chain Prefeasibility Study 21 sector. cut and with ASMED is wash particularly operations. investors interested ASMED interested in in advises collaboration they are related currently to working establishing finishing facilities in Mazar. As well as these carpetfocused project activities, the ASAP project has a website, AgNet, developed internationally. The to Project assist Afghanistan merchants in marketing will have access to this website. 7.2. Training/Capacity Development 7.2.1. NationalLevel Several Ministry of Agriculture, Irrigation, and Livestock (MAIL) associated training and RBSP and capacity activities Livestock Project development operate Program (PHDP), and at (HLP), Support the programs nationallevel. Perennial to potentially These are Horticulture Strategic Planning relevant to Horticulture Development for Sustainable Rural Livelihoods (SSPSRL). None have plans to intervene specifically in the carpet sector. However, each has relevance to RBSP training and capacity development as is further explained below. Both HLP and PHDP advise they have plans to help develop farmer organizations in the districts in which they will be working. Their efforts will focus on utilizing organizations the mechanisms organization RBSP is for delivery development invited to of training collaborate technical be more with them. training. general Should in their nature, SSPSRL has been instrumental in developing a core group of trainers who are currently then as assigned to different Development Unit, a departments within MAIL. The Capacity planned unit in MAIL's newlyestablished Human Resources Department, is expected to be the ultimate homebase for these trainers. SSPSRL has initiated a longterm capacity development effort whereby DAIL lead trainers are trained in training of trainers (TOT) each province. General Following training, lead trainers are trained in Management and Project Management. Two lead trainers have been trained in Bamyan. and TOT in their obtained These involvement whenever trainers in are Project possible. MAIL an important supported has resource training advised for should SSPSRL RBSP be they would like two provinciallevel M&E staff to be trained. Staff have yet to be posted to the field, but plans are to do so. SSPSRL does not currently have plans to provide M&E MAIL and training. collaborate This with is an area where RBSP can assist SSPSRL by ensuring MAIL staff are included in Project M&E training and M&E implementation. 7.2.2. Balkh: Provincial and DistrictLevel The foremost player in carpet in Balkh is ASMED. Balkh is one of five regional centers above, ASMED development, alliance where is ASMED engaged business creation, in projects marketing, association and are private implemented. business development, sector As service noted provider publicprivate workforce capacity sector development. All these developmental activities will reportedly be carriedout in Balkh and will focus, among others, on the carpet sector. Balkh Carpet Value Chain Prefeasibility Study 22 Community Solidarity Development Program, districts in Balkh. Council's and women's provides Councils, have training to through the MRRD National been involved with carpet weaving in some This has shura. supported usually The been Council weavers, accomplished purchases primarily by looms women. the and/or Carpets inputs are sold in local markets, usually in Mazar. The development community in Balkh is large and active. However, current information other NGOs/organizations engaged directly suggests in there carpet are sector no development in Balkh. 7.3. Existing Institutional Capacity Neither MAIL trained in nor its weaving. Department Most provincialdepartments are women at the in employed MAIL in provinciallevel and the in has staff its Department of Home Economics. Building the capacity of women in this department to work with women weavers is an option which merits consideration. 7.4. Existing Groups/Associations The Carpet Producers organization with others, of and traders there Exporters Union representing are about 360 is allegedly traders from the the North. Ministry of Commerce. Union headquarters are in Kabul with satellite offices in Mazar, Herat. The established some working traders trader President the Union relationships having 1,500 organization Export's of is Development with advises large trader numbers 2,000 working looms. the Afghan Association. Along Mazarbased traders in the Union. Established in 1967, the Union is registered with the and largest Hand This Knotted members of The is have weavers second Carpets Association Jalalabad, with largest Manufacturers headquarters in Aqcha in Jawzjan Province. The Association represents 66 traders and 100,000 weavers. The large northern areas, majority other than some weavers in Mazar. organized Dawlat to Abad been association Mazar, There specifically have of are address organized activities are in although they reportedly work with few, weaver via if any, concerns. Community associations Some weavers Development Councils but these are very few and they lack organizational and business skills. Balkh Carpet Value Chain Prefeasibility Study 23 in 8. CREDIT MAP: BALKH CARPET23 The MISFA microfinance organizations working in the province Project provinces have products been (Tables surveyed 67). to Note obtain that information on and marketers will be seeking loans from organizations providing loans large than MFIs The and NBFIs minimum clients equity may transfer were is on exactly how discussions an The equity MFI many with to critical necessary organizations. know is require it surveyed to information know reports MISFA This will be an the clients the their as To the SME/commercial minimum these equity. potential justify the equity minimum equity required by these through MISFA the will MFIs let provide the Project loans. Based Project will be able to request and obtain specific information about the number chains. determine transfer. Project loan Banke Millie also has a loan product and is operating in Balkh. Because the processors banks their added and size requirement of on loans the in its value MFIs and a condition of the MISFA contract. The extent of any additional detail may be problematic when negotiating with MISFA24. Note that since the Project have no relationship institution no report outside on their with MISFA Banke or for Millie loans or any above other the will financial MISFA MFI limit participation in the Project will be available. 23 Where possible the numbers provided by the MFI were checked against those reported to MISFA. Where different the MISFA numbers were used. 24 MISFA has had a bad experience with ADB in the past in terms of delays and people changing their minds. This will not give the Project much room to make demands. Balkh Carpet Value Chain Prefeasibility Study 24 Table 6. MISFA Loan Status District No District 2 3 4 5 City Districts Khulm Shortapa Kushenda Active 1 7 Charbolak 9 10 Chemtal 12 13 14 15 Dawlat Abad Kaldar Shulgara Dehdadi Marmal Total 29,351 4,957 1,089 7 11 Nahrishahi Zari (total) 3,675 8 Balkh Chargumbad Clients 6 1,781 1,501 22 6,090 3,313 2 15 51,803 Active Borrowers (total) 2,802 935 1 2 23,389 4,084 1,416 1,111 4,720 3,137 41,597 Loans Disbursed (number) 8,184 76,382 6,139 7 19,281 3,205 5,123 7 8,968 21,003 1 4 148,304 Loans Disbursed 1,038,226 ($) 36,048,132 2,057,536 4,000 5,362,233 1,031,146 4,300 2,542,371 2,623,617 5,850,750 500 2,100 56,564,912 Loans Outstanding ($) 273,589 701,913 416 1,172 9,913,288 1,106,255 786,862 234,781 800,546 15,157,088 Source: MISFA Consolidated as of March, 08 1,338,266 At the association formation stage all microfinance financial institutions will be invited producers. It to introduce will then be themselves and up MFIs and the producers to connect to the their products to the and access credit. Balkh Carpet Value Chain Prefeasibility Study 25 Table 7. MFIs in the Districts Area Dawlat Abad Group Monthly X X District Individual Frequency X Terms Loan Sizes Repayment Rate FINCA MISFA FMFB FMFB MF OXUS WOCCU Banke X X X X X X X X X X X Millie X SME Microfinance ARMP Nahrishahi District Months 424 1st Loan Max. BRAC X Interest25 MFIs Operating in Types of Lending 15.6 F Number of Clients Payment X X X X 612 17.5 F Weekly 512 24 F Biweekly 412 15 F Monthly 636 15 F Monthly 618 18 F Biweekly/ 612 24 D Monthly 12 12 D Monthly $500 $20 $160 $200 $30,000 $100 $500 $5,000 3,890 59.6% 20,738 96.7% Monthly 6,511 65% 6,522 100% 49 100% 2,643 74.15% 1,275 99.35% N/A N/A SME/Commercial AIB debt AFC 20% ARFC Azizi BRAC Millie service Minimum equity ratio 50% 30% Bank 25% 66% Nat'l Bank Kabul 50% Pashta ny Note: Banks and NBFIs Pakistan N/A 70% See Annex 2 for details. 25 F = Flat, D = Declining Balkh Carpet Value Chain Prefeasibility Study required 26 9. PROPOSED INTERVENTIONS The Project districts will with respectively. districts Weaving a is Abad the less Dawlat is have trained of has major increasing. in the in most and 66,009, and weavers of and newlysettled Shahi 38,791, all district Nahri Nahri Balkh in Shahi, Afghans in Balkh. although Nahri its Shahi weaving. The Governor of Balkh has allocated land for a carpet weaving village in Nahri infrastructure--housing, Dehdadi, producing Dehdadi Many carpet Abad, 79,638, carpet widespread importance been in population Dawlat and is operate power, and Shahi. water--are Reports are beginning to be developed. Dawlat Abad and Dehdadi also have a significant number of sheep, adding to the locations is district availability good. where of Electric the raw power fertilizer plant wool. is Road most is access to these available in Dehdadi located. Water is abundant in Dehdadi, much less so in Dawlat Abad and Nahri Shahi. 9.1. Description 9.1.1. Production The Project will assist weavers to access highquality carpet inputs such as looms, yarn, and designs. Via the Project, weavers will learn about and testout new spinning wheels to increase their spinning productivity. Through an extension program, the Project will increase weaver capacity in various wool valueadded activities, emphasizing improved dyed and spun wool. To create a core of dying advanced and marketing weavers, of selected weavers will be trained in carpet weaving Best Practices. A critical component trained of the Project extension and program be qualityimprovement whereby MAIL extension staff will technically backstop the weaving process and assist weavers 9.1.2. Processing will to improve the quality of their carpets. To establish Project the will feasibility support a impact wool feasibility (washing/drying/storing) environmental of and will assessment. scouring study support If of a operations, wool wool feasible the scouring scouring and if facility any negative environmental impacts can be appropriately mitigated, the Project will assist investors To in establishing facilities in appropriate and strategic locations. facilitate Project the will facility. establishment support If an negative of a cut environmental environmental and impact impacts wash facility, assessment of the such can be appropriately mitigated, the Project will assist investors in establishing a cut and facility in an appropriate and strategic location. scouring staff and to finishing operate and environmental issues facilities, maintain as the Project facilities. well as For both will Training the train will wash facility consider Best Practices. 9.1.3. Marketing The Project will work closely with existing trader unions and associations to build their the organizational Project Carpet will traders assist will and in be business capacity. developing trained in As additional may be marketing needed, groups. various Balkh Carpet Value Chain Prefeasibility Study 27 procedures to improve their valueadded activities and volume of sales. Procedures will customs include, clearance, marketing will be and for example, marketing emphasized. by inventory air Traders and management, sea. Ecommerce attend learn with national how to ASMED, trade engage the fairs. Project The direct will be assisted to develop websites and they will be linked to international markets via collaboration branding, will Project support will help AgNet. Balkh Balkh traders traders Government in constructive dialogue and how to articulate their positions and concerns 9.1.4. Association Development to Government. In to The strengthening new weaver Project. and By of existing trader the end and the associations of the organization will Project, be a development priority of of the Associations will be selfsustaining. 9.1.5. Staff Capacity Development To implement the Project successfully, training will be provided for various Project staff primarily in wool selected dying aspects and of spinning the and carpet value chain, carpet weaving and marketing. To the extent possible, Project staff trained for this value chain will be women as they can work with women weavers more readily than can men. The Project will train DAIL female staff to participate in the Project on a parttime basis. This will help build capacity in the industry in general and in DAIL in specific. 9.2. Strategic links to existing programs Consideration Afghanistan should Carpet be given across all AREDP its MAIL's participation on the Committee. As AREDP becomes operational, the strategic linkages between the projects detailed. to proposes will to need integrate activities. This is to be further business an area discussed development where RBSP services clients well benefit and offers one specific area for strategic linkages. further explore and may RBSP will the concept of joint venture with ASMED to facilitate the development of wool scouring and/or cut and wash facilities in Mazar. The AgNet website, developed by ASAP, will be available for use by RBSP clients. 9.3. Stakeholders Interest in Value Chain Improvement The with Carpet RBSP. Producers Within and Exporters Union is ready to collaborate this group are merchants who are eager to build their businesses and learn more about international markets. contacted were interested in Project participation. All weavers They asked many questions regarding the conditions of participation and were advised information would be forthcoming as such decisions are finalized. of the carpet traders in Balkh advise they are this Several interested in establishing better facilities Balkh. Merchants for in wool the scouring, spinning, dying, and storing in province have also indicated interested in establishing cut and wash facilities in Balkh. . Balkh Carpet Value Chain Prefeasibility Study 28 10. INDICATIVE NUMBER OF POTENTIAL BENEFICIARIES There are an estimated 26,350 families in the three target districts. The Project plans to involve qualityimprovement around focused 600 of extension these intends to support 200 in a program carriedout largely by female extension workers. On a more intensive level for Project families weavers' fewer access weavers, to the highquality inputs (looms, spinning wheels, designs); improve 200 weavers' skills in various value added activities (cleaning, dying, spinning); and train 300 weavers in Best Practices in order support the ten weavers, carpet weaver to improve Project weaving plans associations, to quality. promote involving up the to To further organization 1,000 of weavers and to assist existing carpet marketing associations to develop more effective associations, involving up to 100 traders and weavers. The Project plans to work with eight groups of investors to facilitate the development, if feasible, of a wool scouring facility, of five drying and storage warehouses, and two cut and wash facilities. The number of direct beneficiaries will be dependent on the number will impact a far of larger beneficiaries will be in general. with the north existing traders to in trader improve investors number in of each These traders and weavers not only in Balkh The Project associations their and activities beneficiaries as secondary expects Province but to work intensively specifically with twenty capacity to direct market as well as negotiate effectively with Pakistani buyers. Balkh Carpet Value Chain Prefeasibility Study 29 group. 11. RECOMMENDATIONS 11.1. Feasibility Those weavers who purchase a steel loom for $300 will need to service their loom loan off at and will 25%. outright help Within own establish two the two years loom. cut the The and wash weavers are investors, facilities able who to the for pay Project $105,000 each, are each projected to cut and wash 90,000 sq.m. per annum. The cost of cutting carpet and washing for labor, consumables.26 The 90,000 sq.m. electricity, capital is and projected to chemicals, investment be $4/sq.m. water, and of various includes land, building, drainage, equipment, washing material, cutting machine, power stabilizer, etc. A loan on $70,000 will cost the investor 25%. At a cut and wash price of $4.89/sq.m.27, and operating and interest costs of $4/sq.m. and $0.194/sq.m., resp., the return on investment is 179%. 11.2. Cost Effectiveness The Project's guaranty of investment about cost includes carpet packing for cut and house, investment the wool Project is transfer or a scouring wash and equipment facilities, $25,000 for in wool and $25,000 branding $377,250. interventions dying, and drying building, for carpet estimated the carpet increase value storage, $50,000 access their wool and other inputs Total in chain is two and for revenue form $4,046,130. Weavers independently Availability of water for cut and wash Willingness of carpet traders to keep carpets in Balkh for cutting and washing and to Peshawar with for inventory advertising. The and 11.3. Risk Manageability Table 8. Risks and Risks Management Risks the loan $58,500 for inputs including looms, $67,250 for wool cleaning, scouring, wool spinning $100,000 equity marketing versus exporting existing arrangement How Managed The Project will assist those weavers in inputs and linking the weavers accessing quality with cut and wash and exporters that market branded Afghan carpets directly to the may need to be drilled by cut and international buyers wash operators Water wells The Project will identify international buyers the willing to buy direct from Balkh and assist cut and wash investors and carpet exporters efficient and cost access necessary inputs and effective international shipping arrangements from Balkh 26 MRRD. 2007. Feasibility Study for Carpet Subsector Plan: Operationalizing Cut and Wash Facilities. Subsector Analysis and Business Plan Development/ North and Northeast/Economic Viability and Technical Feasibility. 27 Landell Mills, Ltd. 2007. Preparing the Commercial Agricultural Development Project, Main Report, Phase 2. Asian Development Bank Project. Balkh Carpet Value Chain Prefeasibility Study 30 11.4. Financial Viability The various value added activities in the wool portion of the carpet value chain are not high return activities. However, spinning wool by use of spinning wheels rather than by to increase looms their gives become their a direct through to and the marketing can Also, chance independent carpets with incomes. them more hand helping build able Project wash facilities buy is their an opportunity buy their own their trade and own local inputs and marketing sell agents A study is needed to determine The high, in assisted, opportunities. women weavers equity to the feasibility of wool scouring. and provide return assuming the on investing difficulties carpets does not present a problem in the winter. in in cut drying the The marketing of carpets direct from Balkh to the international buyer is more expensive the shipping the extra Afghan trade cost costs products barriers from Peshawar incurred through are by the pulled to Afghans Karachi down as the in port international shipping are Pakistan containers likely comes buyer. to than However, of drop as under mounting pressure from the international community. Afghan carpets can enter without import duties, making Afghan carpets more competitive. the US 11.5. Environmental Issues The feasibility environmental assessment wool impact will establishment for of be scouring assessment. conducted any cut and will be Similarly, before wash the accompanied an environmental Project facilities. with supports In both an impact the cases, mitigation measures will be needed to be put in place along with the investments. Balkh Carpet Value Chain Prefeasibility Study 31 ANNEX 1: VALUE CHAIN FOR BALKH CARPET Wholesale & Retail Markets Generic Chain Functions Inputs Provision Provide -Equipment -Inputs Production Weave Carpets Transformation Wholesale/Retail Market Transport Distribute Sell Cut & Wash Chain Operators CONSTRAINTS OR GAPS (Credit & marketing are common constraints across the value chain.) Input Provider Limited Afghan wool facilities inputs Most inputs imported Limited wool dying/ spinning capacity Increase flock size facilities Few improved wool scouring Grade and brand Afghan wool Increase spinning/dying capacity access to quality inputs Limited access to quality Develop scouring Improve value chain actor TA to increase availability of high-quality inputs Conduct feasibility study and environmental impact assessment of wool scouring facilities Assist investors in establishing wool scouring (wash/dry/store) facilities Primary Producer Two few weavers pro-duce high quality carpet training opportunities Low quality looms etc Limited access to markets/updated design Few Lack organization Processor/Trader Few quality cut/wash facilities in Afghanistan Pakistan for finishing quality poor facilities Most carpets shipped to Costs of imported cut & wash chemicals high & Afghan branding lacking Facilitate establishment of finishing Brand finished carpets in Afghanistan Drying and storage of carpets in Afghanistan Trader Limited access to external markets High transport cost Linkage only to Pakistan limits profits Limited influence with GOA on industry issues OPPORTUNITIES FOR VALUE CHAIN IMPROVEMENT Facilitate loom ownership Target training to improve weaving skill Facilitate access to higherquality inputs association-based quality control Build associations & initiate TA to increase high-quality production Increase access to quality inputs (looms, wool, yarn) value (wool dying/ marketing, spinning) Build capacity to add Assist associations Expand sales to other regional and to international markets to advocate with government activities Assist traders Assist merchants to improve direct marketing TA to expand existing and establish new markets Linking traders to international markets using new technology and coaching STRATEGIC INTERVENTIONS (Broker access to credit and support marketing activities across the chain.) Conduct environmental impact assessment on cut/wash facilities investors in establishing cut/wash Assist Train cut/wash operators to improve quality Balkh Carpet Value Chain Prefeasibility Study 32 ANNEX 2: CREDIT MAP: BALKH CARPET28 Financial Institution: ARMP (Afghanistan Rural Microcredit Program) Provincial level: # of clients: 3,890 clients in target districts Average Loan size: about $670 Personal 3rd Loan size (cycles): Loan Product Terms: Payments party Months 1.3% Monthly 152 1.3% Monthly 3,111 $131,000 Individual reference Loan from Guarantee: Shura with Collateral: title deed or property: house or First: $500 maximum $350,756 Animal Second +: up to $3000 Grace period Value outstanding Monthly 617 1.3% guarantee, Minimum equity # of clients Overall: 59.6% Type of Lending: Groups of 48 people 15%, promise to help in recovery. shop Repayment rate: Group Loan Guarantee: Group guarantee, # of Dawlat Abad: 443 as of March 2008 Nahrishahi: 776 as of March 2008 Individuals 85% $2,360,674 outstanding Term Interest rate: Flat Business Loans 50% 1 Month Agriculture 50% 412 Months Husbandry 50% 48 Months 412 624 Months 624 Months $1,866,871 * Previously had housing loans but cancelled, 10 loans remain outstanding with a value $12,048. Other information: Loan officers come from district in which they work Financial Institution: BRAC Provincial level: # of clients: 25,340 clients in target districts $3,907,053 outstanding # of Dawlat Abad: 643 as of March 2008 Nahrishahi: 2,819 as of March 2008 Repayment rate: Overall: 96.7% Average Loan size: about $188 28 Where possible the numbers provided by the MFI were checked against those reported to MISFA. Where different the MISFA numbers were used. Balkh Carpet Value Chain Prefeasibility Study 33 Type of Lending: subgroups of 5) Individuals and with individuals group guarantee Loan size (cycles): First: $20 $300 $variable Maximum Urban Loan Product Terms: Flat Payment 6 Months 9 Months Livestock year 17.5% $1,000 maximum $600 # of clients 24% 0 Monthly Other information: Rural N/A $500 Grace period 17.5% 47 over 1 year Agriculture Increments Value outstanding 6 Months SME loans require a Poverty Alleviation Minimum equity with Individual Loan Guarantee: Collateral: In some cases land title, shop, license guarantor (1535 N/A $1200 $1,000 Term 1st $1200 $10,000 2nd Admin: Poverty Alleviation N/A 17.5% 47 over 1 year Agriculture: N/A N/A SME SME 5% 0 Crops, 0 1 N/A Branch office organizes 2 village groups of 1535 members in each village. One group is for poverty alleviation loans and the other for agriculture loans. Each group is broken group acts as the initial credit committee down into small groups of 5. The two sign as witness to loan contracts. Each small group has a leader. These people manage the small group and make up the management of the village organization. When a person joins they must commit to save a specified amount weekly. 6% interest is paid on the savings. 5% of the loan size must be in savings. Up to 15% of savings may extension be withdrawn for emergency purposes. side of BRAC provides training The to agriculture crop and livestock borrowers. Financial Institution: FINCA Provincial level: # of clients: 6,511 in target districts 157 clients clients Type group), # of clients Dawlat Abad: 0 as of March 2008 Closed operations had Nahrishahi: 0 as of March 2008 Closed operations had 665 Repayment rate: of $ 652,950 outstanding Lending: and Overall: 56.3% Groups of Individuals 1040 Average Loan size: about $161 (women's group), 310 (market Group Loan Guarantee: Balkh Carpet Value Chain Prefeasibility Study 34 Group Before borrowing group members must save 2% of the future loan. This amount is used by the group as insurance against a member's default. of moveable and immoveable assets Community leader reference letter. Individual Loan qualify cycles group in Collateral: deed or Guarantee: and 120% Can of loan and Business Second: $300 $700 Women's 23% Individual Business Biweekly include consumer Loan size (cycles): $8005,000 Minimum equity 612 Months 1st two successful items and title Women's Group $400 $1,200 maximum Third: $500 $1,000 Average Loan size: about $300 Loan Product Terms: Payment can First: $160 Fourth: $800 Markup: Flat after reference of neighborhood or village Shura. property: house or shop Market Group only Pledge Group 70% of Market Group 2nd Monthly N/A 0 # of clients N/A N/A 70% of Grace period inventory 0 inventory 69 Months Term 0 612 Month Value outstanding 1st 2nd 3rd 69 Months 612 Months 5 Months 610 Months Up to 18 Months 2% 3%5 Months 2.33% 6 Mo's 2% 8 Months 2%10 Mo's Biweekly Monthly N/A N/A Biweekly N/A N/A Other information: Primary market is urban. loan methodology. Use Sharia compliant Muragahah Markup on delinquent loans cannot be compounded. Administration costs are included in markup. has a three tier rating system. client at cost plus markup. loans and may start FINCA buys the produce and sells to the Looking in For client performance, FINCA 4th at Qtr SME 2008 and or housing early renovation 2009. Financial Institution: FMFB (First Microfinance Bank) Balkh Carpet Value Chain Prefeasibility Study 35 Provincial level: # of clients: 9,937 $7,165,335 outstanding clients in target districts: N/A works in urban areas only Microfinance loan: $251 Average SME loan: $ 15,492 Overall: approximately 00% $2001500 Microfinance term 5% Minimum equity 0 412 Months 20.4% Declining Payment # of clients Monthly 6,522 for Maximum $5,000 Grace period 15% Flat medium term Microfinance Monthly SME 49 0 Term SME $50,000 Interest 636 Months 15% Flat short $759,138 Value outstanding $6,462,479 Other information: and Repayment rate: Loan size (cycles): $3,00030,000 Loan Product Terms: Average Type of Lending: Microfinance: group and individuals SME: Individual First: # of Most handicrafts. of Other the microfinance areas are loans are to retailers services and transportation. SME loans are traders as well as manufacturing and services. Most Financial Institution: OXUS (Sponsored by ACTED) Provincial level: # of clients: 2,643 in target districts March 2008 Dawlat Abad: 0 as of March 2008 Repayment rate: size: about $192 individuals $460,270 outstanding Nahrishahi: 0 as of Overall: approximately 74.15% Average Loan Type of Lending: Individuals with group guarantee and Individual Loan Guarantee: Collateral: In some cases land title, shop plus two personal guarantors who are (cycles): Group to 20 cycles # of clients $600 Individual local leaders First: Loan size $100 $50 Up $500 Loan Product Terms: Balkh Carpet Value Chain Prefeasibility Study 36 Minimum equity Grace period Term Admin: Flat Payment # of clients Value outstanding Group 50% Individual 1 month 6 Months 50% 18% 0 1218 Months biweekly 18% Monthly 3,100 $410,000 300 $240,000 Clients by activity: Agriculture 66, livestock 54, handicraft and manufacturing 72, trade and services 2448. Other information: Group loans are made up of groups of 5. The group receives the loan with allocations to each individual. to corruption. fringe. Have two branches in Mazar. One is being restructured due Although Agriculture primarily activities in are the city some groups on the encouraged Financial Institution: WOCCU (Islamic Investment and Finance Cooperatives) Provincial level: # of clients: 3,482 in target districts of March 2008 $610,804 outstanding Dawlat Abad: 0 as of March 2008 Repayment rate: Type of Lending: Individuals Guarantee: reference Character Nahrishahi: 10 as Overall: approximately 99.35% Loan size: about $484 Shura, mullah, Individual trade # of clients union Average Loan or mayor, cash flow analysis. (cycles): All employees' loan loan maximum Collateral: In some cases land title has a are the same except government maximum of 35% of annual salary First: $500 Open there after to 20% of the loan portfolio but usually not over $3,000. Normal maximum is $1000 Loan Product Terms: 6 Months Months products Loan size 9 Months 2% Government 2% Monthly 2% Monthly Monthly Trade, Service, Agriculture: employees salary loan Minimum equity is Admin: Declining Business: called pledge savings 0 Manufacturing 24% Crops, Livestock 24% 0 0 6 1 year Grace period Term 1st 2nd Payment Balkh Carpet Value Chain Prefeasibility Study 37 # of clients 1632 733 0 Value outstanding $1,079,175 $589,280 0 Other information: Membership is 100 Afs ($2) is 1,000 Afs ($20) Use Sharia compliant Muragahah loan methodology. on delinquent loans cannot be compounded. in markup. Markup Administration costs are included WOCCU buys the produce and sells to the client at cost plus administration costs. committee meeting. Loans above $1,000 require WOCCU to be at the credit All savings are referred to as either active share savings or term share savings. As part of the ARIES project the first year and a half of operating costs are paid by the credit Share capital to get a loan union must be sustainable and project. cover all Thereafter of its the operating costs. cost For the present time profit is put back into primary capital. of included capital in (8%), operating operating costs. expenses (10%) and profit Interest on savings is 7.58% All (4%) are Staff turnover is low except for Balkh. SME/Commercial Banks and NBFIs Financial Institution: BRAC Bank Provincial level: Unit Office with full branch planed for 2008 # of clients: 77 Dawlat Abad: $526,000 outstanding 0 as of January 2008 Overall: 82% # of clients in target districts Nahrishahi: 0 as of January 2008 Province: 100% Type of Lending: Enterprises Guarantee: 3rd party guarantee from 35 people. or property: unregistered house shop Loan size: Deposit Loan pharmacies) or $4 $10 Repayment rate: preferably Enterprise Loan Collateral: registered but title will 30,000 Development Loan $4 deed accept 10,000 Double 30,000 Medical (licensed hospitals, clinics and $4 10,000 SME Balkh Carpet Value Chain Prefeasibility Study 38 Loan Product Terms: Payments 25% of N/A # of clients inventory N/A Minimum equity N/A Monthly N/A N/A N/A 0 Grace period Value outstanding 0 312 Months Double 312 Months Development Medical 25% of SME 25% of inventory 0 Term Interest rate: Flat Deposits 20% 20% inventory 312 Months 25% of inventory Monthly Monthly 0 20% 312 Months 20% Monthly N/A N/A Other information: BRAC Bank is strictly urban Afs per 2,000 Afs borrowed per month. credit Kabul approval. Bank In unit offices Forced savings of 1,000 Service charge of 1% client must open an Centralized account in which is used for disbursement and repayment. The client signs standing order for up to 12 months to transfer payments to BRAC Bank. Afghanistan International Bank (AIB) AIB's SME loans range from $30300,00029. They do not normally lend to start ups. 3% of the loan portfolio is in agriculture. AIB does not have a minimum equity requirement. They use the debt/servicing ratio of the cash flow. Afghanistan Finance Company (AFC) Minimum equity on leases is 20% Minimum equity: 50% of total project Azizi Bank Afghanistan Rural Finance Center (ARFC) Minimum equity: 25% is the minimum but 30% is the actual minimum. Azizi does very little lending outside of Kabul. Banke Millie In 2006 $2 million cases of Banke to Millie, in cooperation cooperatives cooperatives being for with MAIL, fertilizer. lent Apparently loan sort of a were 50/50 cost sharing. Banke agriculture Millie has four products: agriculture, construction, industry and microfinance. The loan description is microfinance as ($1005000), follows. and Agriculture larger loans have two types loans ($5000 and above) backed by strong collateral or personal guarantees. Both types of loans have a 1 year term with 12% interest. Construction loans also have two types microfinance (up to $10,000) and larger loans $10,000 and above). Both loans have a 1 29 DAB requires audited financial statements for any company to whom a bank lends $250,000 or more. Balkh Carpet Value Chain Prefeasibility Study 39 23 repayment rate, although not disclosed, was very bad. The bank is reluctant to lend for some there formed to obtain the financing. Many of the farmers treated the loans as grants and the without approximately 5 year term and the interest rate ranges from 1215%. Industrial loans start at $10,000 rate is and go 1215%. upward. The Microfinance term is 13 years market and believe opening 6 new developing a interest Millie would not or could not provide the percentage of their loan portfolio made up by is the loans range from $1005000. They have a 1 year term with interest rate of 12%. Banke Millie and branches, Sharia these planning compliant on loan products. entering product Banke the leasing because they that it will attract deposits. Kabul Bank Kabul Bank has a centralized lending system. A majority of their loans are overdrafts for working capital and trade finance. When they do make term loans the minimum equity is 3050% with a 12 month term. The interest rate is 1218% with the majority at 15%. an account with the bank To for obtain a a minimum loan of 6 the client must have months. Most loans are in the $2030,000 range. National Bank of Pakistan The National Bank of Pakistan has a $20 million loan portfolio and lends at 12%. They a soft would loan not of provide them minimum equity approximately 8% from ADB of interest and repay ADB. provide a with a Alternatively loan guarantee the number. The bank wants which they would keep 12% bank would like ADB to mechanism. The bank does mostly working capital loans and only a few term loans. The term loans that they do provide are for 1 year because they do not have any long term deposits to match their lending. Pashtany Bank The Export Promotion Bank was merged into Pashtany Bank in August 2007. Pashtany to become Bank a dropped full the service "Tejaraty" bank. (Trade) from its name Pashtany Bank currently only lends for trade and construction. It has a proposal going to its board that it also lend into the agriculture sector. Term loans are for 1 year. Trade loans require as collateral fixed assets with documents registered with the Ministry of Justice. Collateral for trade loans must be 5080% of the loan. Construction, agriculture and industrial loans will have a 13 year term with the minimum equity 5070% and a 12% interest rate. Balkh Carpet Value Chain Prefeasibility Study